Connector correction devices and methods for correcting same

Abstract: To judge with certainty whether the condition of attachment of each metal terminal is proper, a method and apparatus are provided in which a thinned distal end portion of a lance check pin having guide portions contacts an inner surface of a lance flexing space. The lance check pin, when inserted into the lance flexing space, is kept in a proper posture by the guide portions. Therefore, misjudgment of the terminal position is avoided. In addition, to eliminate the need for a retainer, there is provided a method and apparatus in which metal terminal-inserting jigs are inserted into a connector, so that pressing portions of the jigs are inserted into cavities through insertion holes of a connector housing. Metal terminals disposed in an improperly-inserted position are pushed by distal ends of pressing portions of the jig, and are moved to a properly-inserted position where the metal terminal is held against withdrawal by the engagement portion of a lance. The jigs are reusable, thereby reducing the number of the parts. Even if the metal terminal is disposed in an improperly-inserted position, the metal terminal need not be removed reinserted, and reinspected.

Description: BACKGROUND OF THE INVENTION This invention relates to a jig for correcting metal terminals disposed in a connector, which jig comprises portions abuttable against ends of the metal terminals when the metal terminals are disposed in an improperly-inserted position according to claim 1. Moreover the present invention also relates to a method for correcting the position of at least one terminal disposed within a connector housing with using the inventive jig according to claim 4. Generally, a connector comprises a connector housing of a plastics material in which metal terminals, each fixedly secured to one end of a wire, are mounted, and each metal terminal is retained against withdrawal by a lance (elastic retaining pawl) formed integrally within the connector housing. When the metal terminal is inserted into the connector housing, the lance is flexed downwardly toward a flexing space until the metal terminal is inserted into a proper position, at which point the lance is elastically restored to engage a void formed along a bottom surface of the metal terminal, thereby preventing withdrawal of the metal terminal. With this type of terminal withdrawal prevention construction, a certain degree of a frictional force acts between the metal terminal and the lance when the metal terminal is inserted. The frictional force is of such a degree that the metal terminal cannot be inserted into the housing any further, which may give the impression to an operator that the terminal is reliably secured by the lance, even though it is not properly inserted into the housing. Accordingly, the operator, engaged in the inserting operation, may misunderstand that complete insertion has been achieved, and may stop the inserting operation before the lance actually engages the terminal. However, if the metal terminal is not completely inserted into the proper position where the metal terminal engages the lance in the connector housing, the metal terminal can become withdrawn from the housing during use. Therefore it is necessary to preliminarily inspect the terminal connections to correct any improperly inserted or incompletely connected terminals. Recently, various kinds of connector examination devices have been developed for detecting improper attachment of a metal terminal. The present applicant filed an application (Japanese Patent Application No. 5-281716) shown in Fig. 7. In this construction, a lance check pin 51 is provided in a projected manner in opposed relation to each lance 61 in a connector 60, and the lance check pin 51 is adapted to be inserted into a lance flexing space 63 formed in a connector housing 62. When a metal terminal 65 is completely inserted into a proper position, the lance check pin 51, inserted in the lance flexing space 63, does not strike against the lance 61, but is brought into underlying relation with the lance, as shown at an upper stage in Fig. 7. When the metal terminal 65 is in an improperly-attached condition, the lance check pin 51 strikes against the distal end of the lance 61 that is elastically deformed in the lance flexing space 63, as shown at a lower stage in Fig. 7. In this construction, when the metal terminal 65 is in an improperly-attached condition, with the lance 61 disposed in the lance flexing space 63, the lance check pin 51 strikes against the distal end of the lance 61. Accordingly, the check pin 51 cannot be positioned beneath the lance 61. As a result, improper attachment of the metal terminal 65 occurs. For molding reasons, even when the metal terminal 65 is completely inserted into the proper position, with the lance 61 substantially retracted from the lance flexing space 63 and into the terminal 65, the lance 61 still projects slightly inwardly towards an inner wall surface of the lance flexing space 63. In this connection, a distal end portion 51a of the lance check pin 51 is made smaller in thickness than the lance flexing space 63 so that the lance check pin can be brought into underlying relation to the lance 61. Therefore, a gap is formed between the distal end portion 51a of the lance check pin 51 and the bottom portion of the terminal 65. Therefore, it is possible that when the lance check pin 51 is inserted into the lance flexing space 63, the distal end portion 51a of the lance check pin 51 is inserted into the lance flexing space 63 in a bent, deformed manner, or the lance check pin 51 is inserted obliquely. In such a situation, even when the metal terminal 65 is completely inserted into the proper position, with the lance 61 fully retracted from the lance flexing space 63, the distal end portion 51a of the lance check pin 51 can strike against the slightly-projected portion of the lance 61. As a result, despite the fact that the metal terminal 65 is disposed in the proper position, the lance check pin 51 can not reach the position beneath the lance 61, and therefore it may be erroneously judged that the metal terminal 65 is in an improperly-attached condition. In addition, there have been several proposed devices to confirm and inspect the position of the terminal. For example, a retainer that engages the metal terminal (with which the lance is also engaged) is inserted into the housing when an operator believes that the terminal is in the properly-inserted position, thus providing, together with the lance, a second engagement if the terminal is inserted to a depth where the lance engages a void or hole in the terminal. The retainer is provisionally attached to the connector before the metal terminals are inserted, and in this condition, after the metal terminals are inserted, the retainer is moved into a completely-attached position to engage the metal terminals. At this time, if the metal terminal is disposed in an improperly-inserted position (short of the properly-inserted position), the retainer engages the metal terminal, and can not be moved into the completely-attached position. Thus, the retainer indicates whether the metal terminals have been inserted into the properly-inserted position. If it is judged that any metal terminal has not been inserted into the properly-inserted position, i.e., the retainer engages the metal terminal rather than a recess or the void of the metal terminal, the metal terminal is removed and tried again. In the above method in which the retainer is used to determine proper positioning of the terminals, the retainer, mounted on the connector in the completely- attached position, remains connected to the connector, and even after the inspecting of the terminal is complete, the retainers remain mounted on the connector housings. Therefore, inspection of the terminals requires a permanently mounted retainer for each terminal and therefore the cost and number of the parts required for inspecting terminals is high. Moreover, the retainer merely judges whether the metal terminal is disposed in the properly-inserted position or an improperly-inserted position, and when it is judged that the metal terminal is in the improperly-inserted position, an operator is required to remove the terminal and attempt to reinsert the terminal. After the retainer is attached again, the condition of insertion of the metal terminals is rechecked, thus requiring even more time and labor. Therefore, the overall efficiency of the metal terminal-inserting operation suffers. SUMMARY OF THE INVENTION The present invention has been made under the above circumstances, and an object of the invention is to provide a jig and a method for correcting the condition of insertion of metal terminals, in which the metal terminal-inserting operation can be carried out quite efficiently. According to the present invention, this object is solved by the features of claim 1. Improved embodiments of the inventive jig construction result from the subclaims 2 and 3. In connection with the inventive method the above object is solved by the features of claim 4. Improved embodiments of the inventive method result from the subclaims 5 to 7. According to the present invention, there is provided a method for connecting at least one terminal disposed within a connector housing. The method includes the steps of inserting a pressing portion of at least one jig into a terminal receiving chamber of the connector housing where the terminal is disposed; and sliding the pressing portion in the terminal receiving chamber in a fixed position wherein a recess formed in the jig and adjacent the pressing portion mates with a guide portion formed on the connector housing. The pressing portion slides the terminals into a locking position and confirms that the terminal is in the locking position when the pressing portion is in the fitted position. After correcting the position of the terminal within the connector housing, the jig is removed from the connector housing. Moreover according to the present invention, there is provided a jig for correcting metal terminals disposed in a connector including pressing portions abuttable against ends of the respective metal terminals, when the metal terminals are disposed in an improperly-inserted position, to move the terminals into a properly-inserted position. Each pressing portion may be inserted into the connector through an insertion hole for the associated metal terminal, and abuts against a rear end of the metal terminal to urge the metal terminal toward the properly-inserted position. The pressing portions may be arranged in such a manner as to be disposed on opposite sides of wires fixedly connected to the respective metal terminals and extending from the connector, and can push the respective metal terminals. The jig has a relief portion for preventing the jig from interfering with the wires when the jig is moved to a position where the pressing portions are disposed on the opposite sides of the wires. According to an improved embodiment of the inventive jig, there is provided a connector examination device comprising a connector holder portion for holding a connector having metal terminals inserted therein; a metal terminal-correcting jig having pressing portions abuttable, by relative movement between the holder and the jig, against the respective metal terminals, when the metal terminals are disposed in an improperly-inserted position, to move the metal terminals into a properly-inserted position; and a moving mechanism for effecting the relative movement between the connector holder portion and the metal terminal-correcting jig. According to a further improved embodiment of the inventive jig construction, there is provided connector examination device comprising a connector holder portion for holding a connector having metal terminals inserted therein to constitute a wire harness; a metal terminal -correcting jig having pressing portions abuttable, by relative movement between the connector and the jig, against the respective metal terminals, when the metal terminals are disposed in an improperly-inserted position, to move the metal terminals into a properly-inserted position; a moving mechanism for effecting the relative movement between the connector holder portion and the metal terminal-correcting jig; and a detection device for judging a connected condition of the wire harness. The metal terminal-correcting jig is attached to the connector after the metal terminals are inserted into the connector. If any of the metal terminals is disposed in an improperly-inserted position short of the properly-inserted position, the pressing portion of the metal terminal-correcting jig is abutted against the metal terminal to move it to the properly-inserted position. As a result, the metal terminal, disposed in the improperly-inserted position, is retained against withdrawal by the lance. The metal terminal-correcting jig, after thus attached to the connector, is removed from the connector. Each pressing portion is inserted into the connector through the insertion hole for the metal terminal, and is abutted against the rear end of the metal terminal to move it to the properly-inserted position. The pressing portions are arranged in such a manner as to be disposed on the opposite sides of the wires, and push the respective metal terminals, thereby moving those metal terminals, disposed in an improperly-inserted position, to the properly-inserted position. When the jig is to be moved to the position where the pressing portions are disposed on the opposite sides of the wires, the relief portion is brought into registry with the wires, thereby preventing the interference of the jig with the wires. The connector is held by the connector holder portion, and the relative movement between the connector holder portion and the metal terminal-correcting jig is effected by the moving mechanism, so that the pressing portion is abutted against the metal terminal, disposed in an improperly-inserted position, to move it to the properly-inserted position. The connector constituting the wire harness is held by the connector holder portion, and the relative movement between the connector holder portion and the metal terminal-correcting jig is effected by the moving mechanism, so that the pressing portion 5 are abutted against the metal terminal, disposed in an improperly-inserted position, to move it to the properly-inserted position, and the conducting condition of the wire harness is judged by the conduction detection device. As described above, in the connector examination devices of the present invention, even if the lance check pin is bent or deformed, or if the lance check pin is obliquely inserted into the lance flexing space, the lance check pin can be inserted into the lance flexing space while kept in the proper posture. This positively eliminates the abutment of the lance check pin against the lance, retracted from the lance flexing space, which results from the deformation or oblique insertion of the lance check pin. As a result, to misjudge that the metal terminal is disposed in an incompletely-inserted position although the metal terminal is actually disposed in the proper position, is prevented, and highly reliable examination can be carried out. As described above, in the terminal examination and correcting device and method of the present invention, the metal terminal-correcting jig is attached to the connector, and after correction, is removed therefrom. Therefore the same jig can be repeatedly used for a number of connectors, and it is not necessary to prepare as many jigs as the connectors as is the case with retainers of the prior art. Therefore, the number of the parts is reduced, and the costs can be reduced. If there exists any metal terminal disposed in an improperly-inserted position, the jig, when attached to the connector, can move the metal terminal to the properly-inserted position. Therefore, in contrast with the conventional construction in which it is only possible to check by a retainer whether the metal terminals are disposed in an improperly-inserted position, it is not necessary to remove and then reinsert the metal terminals and to recheck the condition of insertion of the metal terminals. Accordingly, the overall inserting operation for the metal terminals 10 can be enhanced. The metal terminal-correcting jig optionally has the relief portion for preventing it from interfering with the wires, and therefore the plurality of pressing portions to be disposed at the opposite sides of the wires can be provided on a unitary structure. Relative movement between the connector holder portion and the metal terminal-correcting jig can be effected by the moving mechanism, and the operation for moving the metal terminals to the properly-inserted position can be carried out more easily and positively as compared with the case where such an operation is effected manually. The correcting operation for moving the metal terminals, disposed in an improperly-inserted position, to the properly-inserted position, and the examination operation for judging the conducting condition of the wire harness, including the metal terminals, can be carried out at the same time. Further objects, features and advantages of the present invention will become apparent from the detailed description of preferred embodiments which follows, when considered together with the attached figures of drawings. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in detail with reference to the following drawings, wherein: Fig. 1 is a cross-sectional view showing a first embodiment of a connector examination device; Fig. 2 is a fragmentary, enlarged view showing a lance of a connector and a lance check pin; Fig. 3 is a cross-sectional view of the examination device, showing a condition in which the connector is set; Fig. 4 is an enlarged, cross-sectional view showing the positional relation between the lance and the lance check pin in an upper stage of Fig. 3; Fig. 5 is a cross-sectional view taken along the line V-V of Fig. 4; Fig. 6 is a cross-sectional view of a second embodiment of a connector examination device; Fig. 7 is a cross-sectional view of a connector examination device shown for comparison purposes; Fig. 8 is an enlarged, cross-sectional view of a portion of Fig. 7; Fig. 9 is a perspective view of a connector and the terminal correcting apparatus; Figs. 10(A) and 10(B) are sequential, crossectional views of the terminal correcting apparatus in Fig. 9; Fig. 11 is a perspective view of a connector and an embodiment of the terminal correcting apparatus according to the invention; Fig. 12 is a perspective view of a connector and yet another embodiment of the terminal correcting apparatus; and Fig. 13 is a cross-sectional view of a connector and an another embodiment of the terminal correcting apparatus according to the invention. Only the embodiments according to Figs. 11 and 13 are covered by the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS A first embodiment of the terminal inspecting apparatus and method will now be described with reference to Figs. 1 to 5. Reference is first made to the construction of a connector 30 to be examined by the use of an examination device 10. A connector housing 31 is molded of a resin, and has a rectangular configuration as a whole. A plurality of cavities 32 are formed in the connector housing, and are arranged in upper and lower stages. Each cavity 32 extends through the connector housing from its front to its rear end, and a metal terminal 33 is inserted into the cavity 32 from a rear side (i.e., the right side in Fig. 1). The metal terminal 33, having a wire 35 compressively connected thereto, is of a known construction, and is of the female type that mates with a male metal terminal of a mating connector (not shown). Lances 34 for retaining the respective metal terminals 33 against withdrawal are formed integrally on the connector housing 31. The lance 34 is in the form of an elastically-deformable projecting piece, and has a retaining portion 34a formed adjacent to its distal end. The retaining portion 34a projects toward the associated cavity 32. A lance flexing space 32a for allowing downward elastic deformation of the lance 34 is provided within the cavity 32, the lance flexing space being formed utilizing a mold release space. The lance flexing space 32a is open to the front end face of the connector housing 31, and has upper and lower inner surfaces parallel to each other. As will be more fully described later, when the lance 34 holds the metal terminal 33, inserted into a proper position, against withdrawal, a lower surface of the lance 34 is disposed parallel to the lower inner surface of the lance flexing space 32a. The lower surface portion of the lance 34 projects downwardly into the upper inner surface of the lance flexing space 32a (Fig. 4). When the metal terminal 33 is inserted into the cavity 32, the distal end of the metal terminal 33 abuts against the lance 34 during the insertion to urge the lance 34 downward, so that the lance 34 is elastically deformed and projected into the lance flexing space 32a. When the metal terminal 33 is inserted into an innermost portion of the cavity 32, the lance 34, elastically deformed during the insertion, is retracted upwardly from the lance flexing space 32a, that is, restored to its initial position as a result of engagement of the retaining portion 34a in an engagement hole 43a in the metal terminal 33, thereby retaining the metal terminal 33 against withdrawal. To indicate the condition of engagement of the lance 34, the metal terminal 33 in the upper stage (Fig. 3) is shown as inserted into a proper position to be completely engaged with the lance 34, while the metal terminal 33 in the lower stage is shown as disposed in an incompletely-inserted position short of the properly position, with the lance 34 elastically deformed into the lance flexing space 32a. Next, an examination device 10 for examining the above connector 30 will be described. The examination device 10 is incorporated in an inspection or checker housing 11 made of a resin. The interior of the inspection housing 11 is divided by partition walls 11a into a plurality of smaller chambers forming cavities 12 corresponding in number to the cavities 32 in the connector housing 31. The inspection housing has a hood portion 13 of a generally square or rectangular shape disposed adjacent to front ends of the cavities 12, the hood portion 13 serving as a set portion for receiving the connector housing 31 of the connector 30. A slider 14, having excellent sliding properties, is mounted within each cavity 12 for sliding movement therealong, and a lance check pin 15, formed integrally with the slider, projects into the hood portion 13 through a through hole 11b formed in the partition wall 11a. A relatively weak compression spring 16 mounted within the cavity 12 normally urges the slider 14 to a right side in Fig. 1. When the connector 30 is not placed in the hood portion 13, the lance check pin 15 fully projects into the hood portion 13 in such a manner that a stopper 14a, formed on the slider 14 in a projected manner, abuts against the partition wall 11a. The lance check pin 15 is disposed in such a position that it can be inserted into the lance flexing space 32a in the connector housing 31 set in the hood portion 13. The lance check pin 15, when inserted into the lance flexing space 32a, moves in sliding contact with the upper and lower inner surfaces of the lance flexing space. Even when the lance 34 retains the metal terminal 33 against movement from the normal position, the lance 34 slightly projects into the lance flexing space 32a as described above. In this connection, a distal end portion 15a of the lance check pin 15 is cut at its upper surface to be reduced in thickness. Therefore, the lance check pin 15 can be inserted into a position where its distal end portion 15a underlies the lance 34. With this construction, when the metal terminal 33 is disposed in an incompletely-inserted position, with the lance 34 flexed and projection into the lance flexing space 32a, the distal end of the lance check pin 15 abuts against the distal end of the lance 34. In this embodiment, the lance check pin 15 is provided with means by which its distal end portion 15a can be smoothly brought into underlying relation to the lance 34. This construction will now be described. Elongate, wall-like guide portions 15b and 15b are respectively formed on and extend along lateral marginal portions (except for a widthwise central portion registrable with the lance 34) of the upper surface of the distal end portion 15a of the lance check pin 15 that can face the lower surface of the lance 34. The guide portions 15b extend parallel to the direction of the length of the lance check pin 15. Upper surfaces of the guide portions 15b are flush and continuous with the upper surface of that portion of the lance check pin 15 extending rearwardly from the distal end portion thereof, and can be brought into contact with the upper inner surfaces of the lance flexing space 32a. Distal ends of the guide portions 15b terminate a predetermined distance short of the distal end of the lance check pin 15 to provide a relief recess 15c for preventing the guide portions 15b from interfering with stabilizers 33a that project from the metal terminal 33 along the opposite sides of the lance 34. An electrical contact member 17, comprising an electrically-conductive bar, is fixedly mounted on the slider 14, for example, by press-fitting. The electrical contact member 17 extends parallel to the lance check pin 15, and a length of the contact member 17 is shorter than that of the lance check pin 15. The position of the distal end of the electrical contact portion 17 is so determined that when the connector housing 31 is set in the hood portion 13, so that the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, with the metal terminal 33 disposed in the proper position, the electrical contact member 17 contacts the distal end of the metal terminal 33. Each of the electrical contact members 17 is connected to a conduction examination circuit (not shown) via a lead wire 18. This conduction examination circuit judges whether the metal terminals 33 are properly inserted respectively into the cavities 32 in the connector 30 assembled as a wire harness. The conduction examination circuit is a known construction and incorporates a power source for conduction examination purposes, and effects an examination by judging whether electric current can flow between predetermined metal terminals of the two connectors connected respectively to the opposite ends of the wire harness. Next, the operation of this embodiment will be described. The metal terminals 33, compressively connected to respective ends of the wires 35, are inserted respectively into their associated cavities 32 in the connector housing 31, and the wires 35 are combined together into a bundle by tape or the like, thereby assembling the wire harness. In this condition, the examination for improper attachment of the metal terminals 33, as well as conduction examination, are carried out in the following manner. The wire harness to be examined is placed on a predetermined examination plate, and the connector 30 is set in the hood portion 13 of the inspection housing 11 of the connector examination device 10 (see Fig. 3). At this time, if the metal terminal 33 of the connector 30 is disposed in the proper position where it is engaged with the lance 34 of the connector housing 31 as shown in the upper stage of Fig. 3, the lance 34 is retracted upwardly, and projects slightly into the lance flexing space 32a, thereby opening the lance flexing space 32a disposed below the lance 34. Therefore, the lance check pin 15, inserted into the lance flexing space 32a upon setting of the connector 30, will not abut against the lance 34, and the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, with the two guide portions 15b and 15b disposed adjacent respectively to the opposite lateral sides of the lance 34. As a result, by the urging force of the spring 16, the slider 14 is moved forward in such a manner that the lance check pin 15 is fully projected into the hood portion 13 of the checker housing 11. As a result, the electrical contact member 17, movable with the slider 14, is also projected a maximum distance toward the connector 30, so that the distal end of the contact member is brought into contact with the distal end of the metal terminal 33, thus making an electrical connection therebetween. Therefore, it is confirmed by the conduction examination circuit that the metal terminal 33 is disposed in the proper position and that the metal terminal is mounted in the predetermined cavity 32. By contrast, if the metal terminal 33 is disposed in an incompletely-inserted position where it does not contact the lance 34, as shown in the lower stage of Fig. 3, the lance 34 is pressed down by this metal terminal 33, and projects into the lance flexing space 32a. Therefore, when the connector 30 is set in the hood portion 13 of the checker housing 11, the distal end portion 15a of the lance check pin 15 abuts against the distal end of the lance 34, and can not be brought into underlying relation with respect to the lance 34. Therefore, during the setting of the connector 30, the lance check pin 15 is prevented from advancing in the lance flexing space 32a, and the slider 14 is urged left (Fig. 3) relative to the checker housing 11 while compressing the compression spring 16. Therefore, the electrical contact member 17, integrally mounted on the slider 14, is also urged left, and can not contact the metal terminal 33, thus failing to achieve an electrical connection to the metal terminal 33. This abnormality encountered with the metal terminal 33 is detected by the conduction examination circuit. When the lance 34 is urged down into the lance flexing space 32a as described above, the distal end of the lance check pin 15 abuts against the lance 34, and therefore an insertion resistance, produced when setting the connector 30 into the hood portion 13 of the checker housing 11, is increased. Despite this, the setting should be continued. Because the lance check pin 15 is urged left while compressing the compression spring 16, an excessive pressure will not be exerted on the lance 34, and damage to the lance 34 is thereby prevented. In the above examination, there are occasions when the distal end portion 15a of the lance check pin 15 to be inserted into the lance flexing space 32a in the connector 30 is deformed or bent upwardly, or is obliquely and/or upwardly inserted into the lance flexing space 32a. Even in such a case, upon insertion of the lance check pin 15 into the lance flexing, space 32a, the upper surfaces of the guide portions 15b contact the upper inner surface of the lance flexing space 32a over a predetermined length in the direction of the length of the lance check pin 15. In addition the lower surface of the lance check pin 15 contacts the lower inner surface of the lance flexing space 32a. Therefore, the lance check pin 15 is corrected into a proper posture, and can be inserted into the lance flexing space 32a while being guided by guide portions 15b to this posture. As described above, in this embodiment, when the metal terminal 33 is disposed in the proper position, the distal end portion 15a of the lance check pin 15 can be positively brought into the position beneath the lance 34. Therefore, to misjudge that the metal terminal 33 is disposed in an incompletely-inserted position, although the metal terminal is actually disposed in the proper position, is prevented, and the highly-reliable examination can be carried out. In addition, the relief recess 15c is provided at the distal end portion 15a of the lance check pin 15, and when the distal end portion 15a of the lance check pin 15 is brought into underlying relation to the lance 34, the guide portions 15b of the lance check pin 15 will not interfere with the stabilizers 33a of the metal terminal 33, thereby preventing a situation in which the advance of the lance check pin 15 is prevented by the interference of the guide portions 15b with the stabilizers 33a. The electrical contact members 17 can be connected to the conduction examination circuit for the wire harness, and by performing one operation, that is, the setting of the connector 30 in the inspection housing 11, the position of the lance 34 (that is, whether each metal terminal 33 is disposed in the proper position) and whether each metal terminal 33 is mounted in the predetermined cavity 32 can be confirmed at the same time, and the examination operation is made reliable and efficient. Furthermore, the sliders 14 are mounted respectively in the cavities 12 in the inspection housing 11, and the lance check pin 15 and the electrical contact member 17 are integrally provided on each slider to provide a single unit. Therefore, it is only necessary to provide units corresponding in number to the number of poles of the connector 30 to be examined. The integral check pin and electrical contact member 17 can be adapted for inspection of any type of connector. In the event of a malfunction, it is only necessary to exchange such a defective unit, and therefore the maintainability is excellent. Fig. 6 shows a second embodiment of the terminal inspecting apparatus and method. The basic difference from the above embodiment is that this embodiment is of such a construction that an inspection housing 11 is mechanically moved toward a connector 30. Other elements are similar to those of the first embodiment and, therefore, to avoid repeated explanation, identical portions are denoted by the same reference numerals, respectively, and only different portions will be described in detail. The inspection housing 11 is mounted on a base plate 41 for movement to the right and left in Fig. 6, and is moved by pivotally rotating a cam handle 42 about a shaft 42a mounted on the base plate 41. Lance check pins 15 and electrical contact members 17 used in this embodiment are the same as those in the preceding embodiment. A connector holder 43 is fixedly mounted on a left end portion (Fig. 6) of the base plate 41. The connector holder 43 comprises a U-shaped support block 44, a U-shaped back plate 45 releasably mounted on the support block 44, and an upwardly-open connector fixing groove 46 is provided between the support block and the back plate. Elongate protuberances (not shown) formed on an outer surface of the connector housing 31 are fitted in the connector fixing groove 46 from the upper side, and the two elongate protuberances are vertically guided by it, so that the connector housing 31 received by the support block 44 is retained in position. In this condition, the connector housing 31 is immovable in right and left directions. The connector 30, manually or by machine, is fitted or set in the connector holder 43 from the upper side. When the cam handle 42 is pivotally moved in a direction of an arrow 70 to move the inspection housing 11 to the right in Fig. 6, each of the lance check pins 15 and the associated electrical contact members 17 are moved toward the connector 30, and the distal end portion of the lance check pin 15 is inserted into a lance flexing space 32a beneath a lance 34. The electrical contact member 17 is moved toward an associated metal terminal 33, as described above for the preceding embodiment. As a result, the condition of attachment of each metal terminal 33, as well as the connection of the metal terminal 33, is checked. In this embodiment, also, guide portions 15b for keeping the lance check pin 15 in a proper position in the lance flexing space 32a are formed at a distal end portion 15a of the lance check pin 15. Therefore, when the metal terminal 33 is disposed in a proper position, the distal end portion 15a of the lance check pin 15 can be positively brought into a position beneath the lance 34. This eliminates the possibility that it is judged that the metal terminal is disposed in an incompletely-inserted position when the metal terminal 33 is disposed in the proper position, and therefore highly reliable examination can be carried out. In Fig. 6, the inspection housing 11 is moved by pivotally moving the cam handle 42; however, in contrast with this, the checker housing 11 may be fixed while the connector holder 43 holding the connector 30 may be moved, or the two may be moved toward each other. In addition, the judgment means for judging from the position of the lance check pin 15 may be achieved using devices other than the electrical contact member 17 that is mounted for movement with the lance check pin 15. A first embodiment of the inspecting and correcting apparatus and method aspects of the present invention will now be described with reference to Figs. 9, 10(A) and 10(B). Reference is first made to a connector 101 in which a metal terminal-correcting jig 130 of this embodiment is used. A connector housing 102 of a generally square configuration is molded of a plastics material, and the interior of the connector housing 102 is divided into two stages each having a plurality of cavities 103. Each cavity 103 extends through the connector housing 102 from its front to its rear end, and a metal terminal 110 is inserted into the cavity 103 from an insertion hole 104 open to a rear side (i.e., the right side in Fig. 10(A)) of the cavity. When the metal terminal 110 is inserted in the cavity 103, a wire 112, fixedly secured to a rear end portion of the metal terminal 110, extends to the exterior of the connector housing 104 through the insertion hole 104. An elastically-deformable lance 105 for retaining the metal terminal 110 against withdrawal is provided within the cavity 103. An engagement portion 111 for engagement with the lance 105 is provided on the metal terminal 110, the engagement portion 111 being formed by removing part of the surface of the metal terminal. As the metal terminal 110 is inserted into the cavity 103, the lance 105 is elastically deformed away from the metal terminal 110 by contact with the outer surface of the metal terminal 110 until the inserted metal terminal 110 reaches a properly-inserted position. When the metal terminal 110 reaches the properly-inserted position, the lance 105 becomes engaged with the engagement portion 111 because of its elastic restoring force, thereby retaining the metal terminal 110 against withdrawal. To indicate the condition of the lance 105, the metal terminal 110 in the upper stage (Fig. 10(A)) of the connector 101 is shown as inserted into the properly-inserted position, with the lance 105 engaged with the engagement portion 111, while the metal terminal in the lower stage is shown as disposed in an improperly-inserted position short of the properly-inserted position, with the lance 105 disengaged with the engagement portion 111. Next, the metal terminal-correcting jig of this embodiment will be described. In this embodiment, in accordance with the two-stage arrangement of the cavities 103, two metal terminal-correcting jigs 130A and 130B are provided. Each of the metal terminal-correcting jigs 130A and 130B includes a plurality of L-shaped pressing portions 132 that are formed on and project from one side of a base plate 131, and are arranged and juxtaposed in a manner similar to the arrangement of the cavities 103 of the corresponding stage. The bent distal end of each pressing portion 132 projects parallel to the surface of the base plate 131. The metal terminal-correcting jigs 130A and 130B can be attached to the connector housing 102 from a rear side thereof, and the attached jigs can be removed from the connector housing. When the metal terminal-correcting jigs 130A and 130B are attached to the connector housing 102, the pressing portions 132 are fitted respectively in the cavities 103 through the respective insertion holes 104, and are directed forwardly. If the metal terminals 110, inserted in the respective cavities 103, are disposed in their properly-inserted position, the distal end of the corresponding pressing portion 132 inserted into the cavity 103 abuts against the rear end of the associated metal terminal 110 when the metal terminal-correcting jigs 130A and 130B are completely attached into their finally-attached position. If the metal terminal 110 is disposed in an improperly-inserted position short of the properly-inserted position, the pressing portion is brought into abutment against the rear end of the metal terminal 110 before the metal terminal-correcting jig 130A, 130B reaches the finally-attached position. The connector housing 102 is notched over an area extending from the outer surface thereof to each insertion hole 104 to form a guide portion 107 that fits on a proximal portion 133 of the pressing portion 132 of the metal terminal-correcting jig 130. The proximal portion 133 of the pressing portion 132 is fitted in the guide portion 107, thereby guiding the pressing portion 132 into the cavity 103. Next, the operation of this embodiment will be described. The metal terminals 110 are inserted respectively into the cavities 103 in the connector housing 102, the two metal terminal-correcting jigs 130A and 130B are attached to the connector housing 102 from the rear side thereof, and the pressing portions 132 are forced into the cavities 103, respectively, while being fitted in and guided by the respective guide portions 107. At this time, if any of the metal terminals 110 is disposed in an improperly-inserted position, the distal end of the corresponding pressing portion 132 abuts against the rear end of this improperly-inserted metal terminal 110 before the metal terminal-correcting jig 130 reaches its finally-attached position, and the pressing portion moves while urging the metal terminal forwardly, that is, toward the inner end of the cavity 103. When the metal terminal-correcting jig 130A reaches the finally-attached position, the metal terminal 110, disposed in the improperly-inserted position, is brought into the properly-inserted position as shown in Fig. 10(A), and the lance 105 engages the engagement portion 111 thereof, thereby retaining the metal terminal against withdrawal. With respect to the metal terminals 110, which have been completely inserted into their respective properly-inserted position from the beginning upon insertion into their respective cavities 103, their mating pressing portions 132 abut respectively against the rear ends of these metal terminals 110 when the metal terminal-correcting jigs 130A and 130B are completely attached in their finally-attached position. After the metal terminal-correcting jigs 130A and 130B are thus attached to the connector housing 102, the metal terminal-correcting jigs 130A and 130B are removed from the connector housing 102. At this time, because the pressing portions 132 of the metal terminal-correcting jigs 130A and 130B are merely abutted against the metal terminals 110, respectively, each metal terminal 110 is not subjected to a force acting in a direction of withdrawal of the metal terminal 110 from the cavity 103 when the metal terminal-correcting jig 130A, 130B is removed. Therefore, all of the metal terminals 110 attached to the connector housing 102 are held by the respective lances 105 in the properly-inserted position against withdrawal. As described above, if any of the metal terminals 110 is disposed in an improperly-inserted position, the metal terminal-correcting jig 130A, 130B can move this metal-terminal into the properly-inserted position. Therefore, in contrast with the conventional construction in which it is only possible to check those metal terminals, disposed at an improperly-inserted position, by the use of a retainer, it is not necessary to again effect the insertion of the metal terminals and to again check the condition of insertion of the metal terminals. By the use of the metal terminal-correcting jigs 130A and 130B, the overall inserting operation for the metal terminals 110 can be effected with high efficiency. The metal terminal-correcting jigs 130A and 130B of this embodiment, after attached to the connector housing 102, can be removed therefrom, and therefore the same metal terminal-correcting jigs 130A and 130B can be used repeatedly for a number of connectors 101, and there is no need to prepare as many sets of metal terminal-correcting jigs 130A and 130B as the connectors 101. Therefore, by using the metal terminal-correcting jigs 130A and 130B of this embodiment, the number of the required parts can be reduced, and hence the cost can be reduced. Another embodiment of the inspecting and correcting apparatus and method will now be described with reference to Fig. 11. A metal terminal-correcting jig 140 of this embodiment is adapted to be attached to the same connector 101 as in the first embodiment. The connector has a plurality of cavities 103 arranged in two stages. The metal terminal-correcting jig 140 comprises a base member 141 of a generally recumbent U-shape, and a bar-like grip 142 extending from this base member. The base member 141 has two parallel base plate portions 143 and 143 extending in a cantilever manner in a direction away from the grip 142, and a plurality of pressing portions 144 are formed on and project from opposed surfaces of the base plate portions, and are arranged in a manner corresponding to the arrangement of the cavities 103. An open relief portion 145 is formed between the distal end portions of the two base plate portions 143 and 143 of the metal terminal-correcting jig 140. The relief portion 145 prevents the metal terminal-correcting jig 140 from interfering with wires (not shown in Fig. 11) of metal terminals mounted in the connector housing 102 when this jig is to be attached to the connector housing 102. When the metal terminal-correcting jig 140 is to be attached to the connector housing 102, the two base plate portions 143 and 143 are so positioned that the wires, extending rearwardly from the connector housing 102, are disposed between the two base plate portions 143 and 143, and the pressing portions 144 are fitted in the cavities 103, respectively. Here, for positioning the metal terminal-correcting jig 140 in straddling relation to the wires, the relief portion 145 is disposed in facing relation to the lateral sides of the wires, and then the metal terminal-correcting jig 140 is moved perpendicularly to the wires, so that the wires are received in a space between the two base plate portions 143 and 143. By doing so, interference between the metal terminal-correcting jig 140 and the wires can be avoided. For removing the metal terminal-correcting jig 140 from the connector housing 102 after the jig is attached to the latter, the metal terminal-correcting jig 140 is moved perpendicularly to the wires in such a manner that the wires are moved out of the space, between the two base plate portions 143 and 143, through the relief portion 145. Interference between the metal terminal-correcting jig 140 and the wires can be avoided. Another embodiment of the inspecting and correcting apparatus will now be described with reference to Fig. 12. Two metal terminal-correcting jigs 150A and 150B are used as one set. The metal terminal-correcting jigs 150A and 150B are attached to the same connector 101 (having a plurality of cavities 103 arranged in two stages) in such a manner that each metal terminal-correcting jig cooperates with the cavities of the corresponding stage. Each of the metal terminal-correcting jigs 150A and 150B has a base member 151 in the form of an elongate bar, and a plurality of juxtaposed elongate pressing portions 152 are formed on and project from one side of the base member 151. The pressing portions are arranged in a manner corresponding to the arrangement of the cavities 103 of the corresponding stage. Thus, each of the jigs assumes a comb-shape as a whole. The metal terminal-correcting jigs 150A and 150B are attached to the connector housing 102 from a rear side thereof in such a manner that the pressing portions 152 are forced into the cavities 103, respectively. If any of metal terminals (not shown) inserted in the respective cavities 103 is disposed in an improperly-inserted position, such a metal terminal is urged by the distal end of the pressing portion 152 to be moved into a properly-inserted position, and is held there against withdrawal by a lance (not shown). Thereafter, the metal terminal-correcting jigs 150A and 150B are removed from the connector housing 102, and are used for attachment to another connector. Another embodiment of the inspecting and correcting apparatus will now be described with reference to Fig. 13. A connector examination device 160 of this embodiment comprises a metal terminal-correcting jig 162 fixedly mounted on a base plate 61 adjacent to one end thereof, a connector holder 164 that is mounted on a rail 163 for movement toward and away from the metal terminal-correcting jig 162, and is urged in a direction away from the metal terminal-correcting jig 162, and a cam handle 165 for moving the connector holder 164 toward the metal terminal-correcting jig 162. The connector holder 164 holds the connector 101 (having a plurality of cavities 103 arranged in two stages) and has a connector holder portion 166 that is open toward the metal terminal-correcting jig 162 (that is, to the right in Fig. 13) and also toward a front side of the sheet of Figure 13. The connector 101 is moved parallel to be received in the connector holder portion 166 from the front opening in such a manner that the direction of insertion of metal terminals 110 is kept parallel to the rail 163, with wires 112 extending toward the metal terminal-correcting jig 162. The connector 101, received in the connector holder portion 166, is held against movement by means (not shown). Insertion holes 104 of the cavities 103 in the connector 101 received in the connector holder portion 166 are open in facing relation to the metal terminal-correcting jig 162. The metal terminal-correcting jig 162 has an open relief portion 167 that is open on its opposite sides (right and left sides in Figure 13) in the direction of the length of the wires 112 of the connector 101 held in the connector holder portion 166, and is also open toward the front side of the sheet of Figure 113. A plurality of pressing portions 168 are formed on and project from opposed inner surfaces of the relief portion 167, and are arranged in a manner corresponding to the cavities 103 arranged in two stages. The pressing portions 168 are opposed respectively to the insertion holes 104 of the cavities 103 in the connector 101 held in the connector holder portion 166. The cam handle 165, which serves as a moving mechanism, is pivotally supported on a shaft 169 at that side remote from the metal terminal-correcting jig 162, with the connector holder 164 disposed between the cam handle and the jig 162. When the cam handle 165 is pivotally moved in a clockwise direction in Fig. 13, the connector holder 164 is urged by this cam handle 165 to move to the right in Figure 13, that is, toward the metal terminal-correcting jig 162. When the connector examination and correction device 160 of this embodiment is to be used, the connector 101 is first received in the connector holder portion 166 through the front opening (Fig. 13) in the connector holder 164, and the wires 112, extending form the connector 101, are received in the relief portion 167 through the front opening (Figure 13) in the metal terminal-correcting jig 162. In this condition, the cam handle 165 is pivotally moved to urge the connector holder 164 toward the metal terminal-correcting jig 162, and the pressing portions 168 are fitted respectively in the cavities 103 through the respective insertion holes 104. During the movement of the connector holder 164, if the metal terminal 110 is disposed in an improperly-inserted position as shown in the lower stage of the connector in Fig. 13, the rear end of the metal terminal 110 abuts against the distal end of the associated pressing portion 168, so that this metal terminal 110 is moved in an opposite direction relative to the connector 101 to finally reach a properly-inserted position. Simultaneously with this, the other pressing portions 168 respectively abut against the rear ends of the metal terminals 110 disposed in their respective properly-inserted position. If all of the metal terminals 110 are disposed in the properly-inserted position from the beginning, all of the pressing portions 168 abut against the rear ends of the metal terminals 110, respectively. After the connector holder 164 is thus moved, the cam handle 165 is returned to return the connector holder 164 to its initial position, thereby disengaging the connector 101 from the pressing portions 168. Then, the connector 101 is removed from the connector holder portion 166, and the wires 112 are removed from the relief portion 167 of the metal terminal-correcting jig 162. Thereafter, the above operation can be effected for another connector 101. The present invention is not limited to the above embodiments. For example, in the terminal correction embodiments, although the cavities in the connector are arranged in the two stages, the present invention can be applied even if the cavities are arranged in a single row or in three or more stages. Where the cavities are arranged in three or more stages, one metal terminal-correcting jig is provided for each stage. Alternatively, the metal terminal-correcting jig can include an integral construction having a comb-like shape to cover each stage, in which case the pressing portions are formed on cantilever portions of the jig. In Figure 13, the metal terminal-correcting jig 162 having the pressing portions 168 is fixedly mounted, and the connector holder 164 having the connector holder portion 166 is movable toward and away from the metal terminal-correcting jig 162. However, in the present invention, the connector holder can be fixedly mounted, and the correcting block can be movable toward and away from the connector holder. In the above terminal correction embodiments, each pressing portion of the metal terminal-correcting jig abuts against the rear end of the associated metal terminal to urge it from the improperly-inserted position to the properly-inserted position. However, in the present invention, means for pushing the metal terminals by pressing portions may be provided by a construction in which an open groove (not shown) in communication with the cavities is formed in the outer surface of the connector housing, and the pressing portions are inserted into the respective cavities through the open groove, and are engaged respectively with engagement portions formed at the respective metal terminals to urge the metal terminals. in the terminal examination apparatus, the relief recess 15c at the distal end portion of the lance check pin 15 can be formed if necessary. Various modifications can be made without departing from the scope of the invention as defined in the appended claims.

Claims: A jig (130; 140; 150; 162) for correcting metal terminals (110) disposed in a connector (101), said jig (130; 140; 150; 162) comprising portions (132; 144; 152; 168) abuttable against ends of the metal terminals (110) when the metal terminals (110) are disposed in an improperly-inserted position, characterized in that said portions are formed as L-shaped pressing portions (132; 144; 152; 168), said pressing portions (132; 144; 152; 168) are projecting from one side of a base plate and the distal end of each pressing portion projects parallel to the surface of the base plate and said portions are formed so as to move the terminals (110) into a properly-inserted position, wherein said pressing portions (132; 144; 152; 168) are inserted into the connector (101) through insertion holes (104) for the metal terminals (110), and abut against rear ends of said metal terminals (110) so as to urge the metal terminals (110) toward the properly-inserted position, wherein said pressing portions (132; 144; 152; 168) are arranged in such a manner as to be disposed on opposite sides of wires (112), respectively, which wires are fixedly connected to the metal terminals (110) and extend from the connector (101), the pressing portions (132; 144; 152; 168) being adapted to push the respective metal terminals (110), and wherein each jig (130; 140; 150; 162) presents two base portions connected to each other by a relief portion (167) so as to prevent said pressing portions (132; 144; 152; 168) from interfering with the wires (112) when said jig (130; 140; 150; 162) is moved to a position where said pressing portions (132; 144; 152; 168) are disposed on opposite sides of the wires (112) with respect to the metal terminals (110). A connector examination device (160) using the jig of claim 1, comprising: a connector holder (164) for holding a connector (101) having metal terminals (110) inserted therein; a metal terminal-correcting jig (162) having pressing portions (168) abuttable, by relative movement between said connector holder (164) and said jig (162), against the metal terminals (110) when the metal terminals (110) are disposed in an improperly-inserted position, to move the metal terminals (110) into a properly-inserted position; and a moving mechanism (165, 169) for effecting the relative movement between said connector holder (164) and said metal terminal-correcting jig (162). A connector examination device according to claim 2, further comprising detection means for judging a connected condition of said wire harness. A method for correcting the position of at least one terminal (110) disposed within a connector housing with using the jig of claim 1, said method comprising: inserting a pressing portion (168) of at least one jig (162) into a terminal receiving chamber (103) of said connector housing (102) where the terminal (110) is disposed; sliding the pressing portion (168) in said terminal receiving chamber (103) into a fitted position wherein a recess formed in the jig (162) and adjacent said pressing portion (168) mates with a guide portion formed on the connector housing (102), the pressing portion (168) sliding the terminal (110) to a locking position and confirming that the terminal (110) is in the locking position when the pressing portion (168) is in the fitted position; and removing the jig (162) from the connector housing (102). The method of claim 4, wherein said at least one terminal (110) is a plurality of terminals, the method further comprising providing each leg of an U-shaped frame member with at least one jig (162), passing a plurality of wires (112) associated with the terminals (110) through an open end of the U-shaped frame member, and engaging said at least one jig (162) provided on each leg of the U-shaped frame with one of the terminals (110). The method of claim 4, further comprising mounting said pressing portion (168) on an elongate arm, said pressing portion (168) matching a configuration of the connector housing (102) to which it is to be engaged. The method of claim 4, wherein the connector housing (102) is supported on a first support (164), the at least one jig (162) is supported on a second support (161), and the first and second supports are moved toward one another to engage the jig (162) with the terminal (110).

Inventors: AOYAMA MASAHIKO, ATSUMI KEIGO, SAIJO EIJI, AOYAMA, MASAHIKO, ATSUMI, KEIGO, SAIJO, EIJI
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1994
Main classification: H01R43
IPC codes: H01R13, H01R43